Rear Right Interior Corner Has Rust

[Tnraits]

Hi guys,

Looking for insight here on my 02… what started as replacing the rear hinges turned into this chaos of a project. The rear passenger side corner where the roll cage meets the tub wheel well and floor behind the front passenger has some rust. The spot that was cut out had a sizeable rust hole there from unknown water leaking (lots of ignorance, but we move on). I’m wonder what some may suggest for best course of action? Currently 1/4 of the roll cage is out from trying to address this. I am hopeful to get it back to normal working condition looking as close to factory if possible. Not trying to part out or buy a new tub unless last resort.

Located in CT, jeep is in central CT atm. If anyone knows a reputable shop that could look at it and also give insight or a quote, I’d happily entertain that too.

Overall the jeep is in decent shape, was my first vehicle as a kid. Frame is meh, has ~170k miles, rides smooth and interior is fairly clean. I added an old picture of it before I took majority of the interior apart.

 

[macleanflood]

Well if you're not in the mood to swap tubs then either getting patch panels or making your own and welding them in is the way to go.

I'm with David Frieburger... don't get it right, get it running.

Do what you need to do to get it back on (or off) the road and enjoy it.

-Mac

 

[Vtx531]

Insight - I have an 02. First vehicle when I was a kid. Literally took it for the first drive today after working on it for the last 3 years. Started with similar issues as yours. Not sure I can recommend going down the rabbit hole. Wouldn't be surprised if you need all new floor pans, rockers are probably rusted out under the Sahara panels and at the rear flares. The further you go, the worse it is going to get.

I would weld, bolt, screw some flat plate over the big hole. Then get everything put back together and drive it until it falls apart or list it for sale.

 

[JMT]

Insight - I have an 02. First vehicle when I was a kid. Literally took it for the first drive today after working on it for the last 3 years. Started with similar issues as yours. Not sure I can recommend going down the rabbit hole. Wouldn't be surprised if you need all new floor pans, rockers are probably rusted out under the Sahara panels and at the rear flares. The further you go, the worse it is going to get.

I would weld, bolt, screw some flat plate over the big hole. Then get everything put back together and drive it until it falls apart or list it for sale.

Yeah, @Tnraits, what he said. I’ve watched some of his work. It’s a long journey. I’ve done some of this type of work myself. It’s a lot. Doable, but a lot.

 

[Tnraits]

Well if you're not in the mood to swap tubs then either getting patch panels or making your own and welding them in is the way to go.

I'm with David Frieburger... don't get it right, get it running.

Do what you need to do to get it back on (or off) the road and enjoy it.

-Mac

Well if you're not in the mood to swap tubs then either getting patch panels or making your own and welding them in is the way to go.

I'm with David Frieburger... don't get it right, get it running.

Do what you need to do to get it back on (or off) the road and enjoy it.

-Mac

Appreciate it. Any recommendations on where to get patch panels for the interior corner? I’ve found parts for the floor and exterior corner but not yet for the inside.

 

[Tnraits]

Insight - I have an 02. First vehicle when I was a kid. Literally took it for the first drive today after working on it for the last 3 years. Started with similar issues as yours. Not sure I can recommend going down the rabbit hole. Wouldn't be surprised if you need all new floor pans, rockers are probably rusted out under the Sahara panels and at the rear flares. The further you go, the worse it is going to get.

I would weld, bolt, screw some flat plate over the big hole. Then get everything put back together and drive it until it falls apart or list it for sale.

Thank you! It actually doesn’t look too bad down in the corner. Seems to be majority surface rust. My dad and I thought about welding in a plate on top as well. My only worry is if the plate is on top of the wheel well covering the whole, will the roll cage line up.

 

[Tnraits]

Yeah, @Tnraits, what he said. I’ve watched some of his work. It’s a long journey. I’ve done some of this type of work myself. It’s a lot. Doable, but a lot.

Appreciate it. For sure is a long journey, I’ve done a lot of work to this thing and it seems to be never ending. The jeep has been sitting longer than I would have liked, so I’m trying to revive this again because I miss driving it.

 

[JMT]

Appreciate it. For sure is a long journey, I’ve done a lot of work to this thing and it seems to be never ending. The jeep has been sitting longer than I would have liked, so I’m trying to revive this again because I miss driving it.

Drive it brother.

The only way to get rid of rust is to get rid of all of it. It's like a cancer. It just keeps growing. If the frame is not so good and the tub is rusting out, then sell it, go south and buy one outside the rust belt. Save yourself a million hours.